CN115280586A

CN115280586A - Battery pack

Info

Publication number: CN115280586A
Application number: CN202180020691.XA
Authority: CN
Inventors: M·J·佩纳; C·R·舒尔茨
Original assignee: Milwaukee Electric Tool Corp
Current assignee: Milwaukee Electric Tool Corp
Priority date: 2020-02-25
Filing date: 2021-02-24
Publication date: 2022-11-01
Anticipated expiration: 2041-02-24
Also published as: EP4111527A4; US11973237B2; CN115280586B; US20210265693A1; EP4111527A1; WO2021173606A1

Abstract

A battery pack is configured to be coupled to a power tool. The battery pack includes a housing having a cavity. The battery pack includes a battery cell holder having a first bracket and a second bracket. The first and second brackets support a plurality of battery cells therebetween. The battery cell support can be configured in different configurations based on the size of the plurality of battery cells supported between the first bracket and the second bracket. The battery pack includes a plurality of mounting features between the housing and the battery cell holder. The plurality of mounting features are configured to alternatively secure a differently configured battery cell holder to the housing.

Description

Battery pack

Cross Reference to Related Applications

This application claims the benefit of U.S. provisional patent No. 62/981,175, filed on 25/2/2020, the contents of which are incorporated herein by reference.

Technical Field

The present disclosure relates to a battery pack, and more particularly, to a battery cell holder coupled to a case of the battery pack.

Disclosure of Invention

In one aspect, a battery pack is configured to be coupled to a power tool. The battery pack includes a battery cell holder having a first bracket and a second bracket. The first and second brackets are configured to be spaced a first distance relative to each other to support a plurality of first battery cells therebetween. The first and second brackets are configured to be spaced a second distance relative to each other to support a second plurality of battery cells therebetween. The battery pack includes a housing having a cavity. The cavity is configured to receive the battery cell holder when the first bracket and the second bracket are spaced a first distance apart. The cavity is configured to receive the battery cell holder when the first bracket and the second bracket are spaced a second distance apart. The battery pack includes a plurality of mounting posts coupled to one of the housing and the battery cell holder and a plurality of mounting apertures formed in the other of the housing and the battery cell holder. The plurality of mounting apertures are configured to enable the first bracket and the second bracket to be secured to the housing when the first bracket and the second bracket are spaced apart a first distance. The plurality of mounting apertures are configured to enable the first bracket and the second bracket to be secured to the housing when the first bracket and the second bracket are spaced apart a second distance.

In another aspect, a battery pack is configured to be coupled to a power tool. The battery pack includes a case having a cavity. The battery pack includes a battery cell holder having a first bracket and a second bracket. The first bracket and the second bracket support a plurality of battery cells therebetween. The battery cell support can be configured in different configurations based on the size of the plurality of battery cells supported between the first bracket and the second bracket. The battery pack includes a plurality of mounting features between the housing and the battery cell holder. The plurality of mounting features are configured to alternatively secure a differently configured battery cell holder to the housing.

In yet another aspect, a method of manufacturing a battery pack. The battery pack is configured to be coupled to a power tool. The method includes providing a housing including a cavity and providing a first cell support including a plurality of first cells. Each of the plurality of first battery cells includes a first length. The first cell holder is configured to be coupled to the housing. The method includes providing a second battery cell holder including a plurality of second battery cells. Each of the plurality of second battery cells includes a second length different from the first length. The second cell holder is configured to be coupled to the housing. The method includes selecting to couple either the first battery cell bracket or the second battery cell bracket to the housing and securing the selected battery cell bracket to the housing.

Other aspects of the disclosure will become apparent by consideration of the detailed description and accompanying drawings.

Drawings

Fig. 1 is a top perspective view of a battery pack.

Fig. 2 is a partially exploded view of the battery pack of fig. 1 showing a battery cell holder received within a lower portion of the housing of the battery pack.

Fig. 3 is a bottom perspective view of the battery cell bracket of fig. 2 in a first configuration.

Fig. 4 is a bottom perspective view of the battery cell bracket of fig. 2 in a second configuration.

Fig. 5 is a bottom perspective view of the battery pack of fig. 1.

Fig. 6 is a bottom view of the battery pack of fig. 1, showing mounting apertures of the lower portion of the housing providing access to the battery cell support for fasteners to couple the battery cell support to the lower portion of the housing.

Fig. 7 is a detailed view of two of the mounting apertures of fig. 6.

Fig. 8 is a flow chart illustrating a method of manufacturing the battery pack of fig. 1 including the battery cell holder of fig. 3 in a first configuration or the battery cell holder of fig. 4 in a second configuration.

Detailed Description

Before any embodiments of the disclosure are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. Terms of degree such as "substantially", "about", "approximately", and the like are understood by those of ordinary skill to refer to reasonable ranges outside of the given value, e.g., the general tolerances associated with manufacturing, assembly, and use of the described embodiments.

Fig. 1 illustrates a battery pack 10 that includes an outer housing 15 having an upper housing portion 20 and a lower housing portion 25. The battery pack 10 also includes a battery cell holder 30 (e.g., a battery cell core; fig. 2) coupled to the outer housing 15 between the housing upper portion 20 and the housing lower portion 25. The housing upper portion 20 includes connection features 35 operable to selectively couple the battery pack 10 to a power tool (e.g., drill, reciprocating saw, grinder, etc.). For example, the connection feature 35 includes rails 40 sized to slidably interface with the power tool and at least one latch 45 that retains the battery pack 10 to the power tool. At least one release actuator 50 is coupled to the housing upper portion 20 and is operable to move the latch 45 to detach the battery pack 10 from the power tool. In other embodiments, the battery pack 10 may be coupled to different instruments (e.g., portable lighting devices, lawn care devices (such as lawn mowers), power saws, blowers). In further embodiments, the battery pack 10 may be configured as a rod-type battery pack (stem-style battery pack).

Referring to fig. 2, the battery cell holder 30 is received within the cavity 55 of the housing lower portion 25 such that the housing lower portion 25 supports the battery cell holder 30. The battery cell holder 30 includes a battery cell 60 (e.g., a cylindrical battery cell) supported between two

brackets

65a, 65 b. Each cell 60 includes a longitudinal axis 62. The battery cell holder 30 also includes a circuit board 70 coupled to a top surface 75 (e.g., top side) of the two

brackets

65a, 65b and in electrical communication with the cell connector 80 and the power tool connector 85. The illustrated cell connector 80 is coupled to lateral sides 90 of the

brackets

65a, 65b and includes contacts 95 that extend through openings formed through both

brackets

65a, 65b to engage ends of the battery cells 60. The illustrated power tool connector 85 is also coupled to the top surfaces 75 of the two

brackets

65a, 65b and provides electrical communication between the battery cell holder 30 and the power tool when the battery pack 10 is coupled to the power tool.

As shown in fig. 3 and 4, the

brackets

65a, 65b include posts 100 (e.g., pedestals) extending from a bottom surface 105 (e.g., bottom side) of the

brackets

65a, 65 b. In the illustrated embodiment, the first bracket 65a includes two

posts

100a, 100b and the second bracket 65b includes two

posts

100c, 100d. Each post 100 on the first bracket 65a is associated with one post 100 positioned on the second bracket 65b in a lateral direction (e.g., parallel to the longitudinal axis 62 of the battery cell 60). For example, the first column 100a is associated with the third column 100c, and the second column 100b is associated with the fourth column 100d. Each post 100 includes a post aperture 110. In some embodiments, the post apertures 110 may be threaded apertures. In other embodiments, the

brackets

65a, 65b may include a total of one, two, three posts 100, etc. In further embodiments, the posts 100 may be located on different portions of the

brackets

65a, 65b (e.g., at least one post 100 may be positioned on the lateral sides 90, the top surface 75, etc.).

With continued reference to fig. 3 and 4, the illustrated battery cell support 30 can support different

sized battery cells

60a, 60b between the

brackets

65a, 65 b. For example, in a first configuration shown in fig. 3, the battery cell holder 30 may support a longer battery cell 60a, and in a second configuration shown in fig. 4, the battery cell holder 30 may support a shorter battery cell 60b. Accordingly, because the battery cell 60a is longer, the battery cell holder 30 of the first configuration includes a first lateral distance 112 (fig. 3) that is greater than a second lateral distance 114 (fig. 4) of the second configuration. In other words, the battery cell holder 30 has a larger dimension (e.g., lateral width) when supporting the longer battery cell 60a than when supporting the shorter battery cell 60b. The first and second lateral distances 112, 114 may be measured between the column aperture 110 of the first column 100a and the column aperture 110 of the third column 100c, or the first and second lateral distances 112, 114 may be measured between the column aperture 110 of the second column 100b and the column aperture 110 of the fourth column 100d. In other embodiments, the first and second lateral distances 112, 114 may be measured between the opposing sides 90 of the first and

second brackets

65a, 65b in a direction parallel to the longitudinal axis 62 of the battery cell 60. In the illustrated embodiment, the first lateral distance 112 is about 0.32 millimeters (mm) greater than the second lateral distance 114. In other words, the battery cell 60a is longer than the battery cell 60b by about 0.32mm. In other embodiments, the first lateral distance 112 may be between about 0.2mm and about 0.5mm greater than the second lateral distance 114. In further embodiments, the first lateral distance 112 may be between about 0.5mm and about 2mm greater than the second lateral distance 114. In yet further embodiments, the first lateral distance 112 may be any distance such that the battery cell holder 30 may be received within the cavity 55 of the housing lower portion 25. In yet further embodiments, the

battery cells

60a, 60b may differ in other dimensions (e.g., diameter, cross-section, etc.) to vary the footprint or size of the stent 30 in the first configuration relative to the stent 30 in the second configuration.

In the illustrated embodiment, the battery cell holder 30 of the first configuration includes a longer battery cell 60a than the total capacity (e.g., amp hour capacity) of the battery cell holder 30 including a shorter battery cell 60b. For example, each cell 60a includes a capacity of about 5 amp-hours (Ah), providing a total capacity of about 15Ah when the cell holder 30 is in the first configuration. Each cell 60b includes a capacity of about 4Ah, providing a total capacity of about 12Ah when the cell holder 30 is in the second configuration. In other embodiments, the total capacity of the first configuration and the second configuration may be different (e.g., anywhere between 1Ah and 25 Ah). Further, the illustrated battery cell holder 30 in either the first configuration or the second configuration includes a nominal voltage of about 18 volts. In other embodiments, the nominal voltage of the battery cell holder 30 may be greater than or less than 18 volts (e.g., 12 volts, 40 volts, etc.).

Referring to fig. 2 and 5, the housing lower portion 25 includes a mounting aperture 115 formed through a bottom wall 120 of the housing lower portion 25 opposite the housing top portion 20. In the illustrated embodiment, the mounting apertures 115 are shaped differently. For example, as best shown in fig. 6 and 7, the pair of first mounting apertures 115a are circular and the pair of second mounting apertures 115b are non-circular (e.g., oval). As best shown in fig. 7, each non-circular mounting aperture 115b includes an inner side 125 and an outer side 130. The inner side 125 is positioned closer to the corresponding first mounting aperture 115a than the outer side 130.

In some embodiments, all of the mounting apertures 115 may be non-circular. In other embodiments, the non-circular shape of the second mounting aperture 115b may be rectangular, triangular, etc. in shape. In other embodiments, the second mounting aperture 115b may be a circular aperture that is larger in size than the first mounting aperture 115a. In further embodiments, the mounting apertures 115 may be located on different portions of the housing lower portion 25 (e.g., at least one mounting aperture 115 may be positioned on a sidewall of the housing lower portion 25) and/or the mounting apertures 115 may be formed through the housing upper portion 20. In still further embodiments, mounting apertures 115 may be formed on the

brackets

65a, 65b, and the post 100 may be coupled to the outer housing 15.

Further, referring back to fig. 2, the housing lower portion 25 includes a plurality of protrusions 135 extending from the bottom wall 120 around each mounting aperture 115a. In the illustrated embodiment, four tabs 135 surround each mounting aperture 115a. In some embodiments, the projections 135 may be rigid and/or may include more or less than four projections. In other embodiments, the tab 135 may be a resiliently biased tab.

During assembly, the illustrated outer housing 15 is sized to support the battery cell holder 30 in the first configuration (fig. 3) to provide a higher output battery pack (e.g., 15 Ah) or in the second configuration (fig. 4) to provide a lower output battery pack (e.g., 12 Ah). Accordingly, the outer housing 15 may be used to support different configurations of the battery cell holder 30 than a housing that may only support one particular battery cell holder, so the use of the outer housing 15 is increased. For example, different cell holder platforms (e.g., 12Ah, 15Ah, etc.) may utilize the same outer housing 15, thus reducing the manufacturing costs associated with producing a particular outer housing for each platform.

In particular, fig. 8 shows a method 140 of manufacturing the battery pack 10. Step 145 includes providing the housing lower portion 25, step 150 includes providing a first battery cell support 30 in a first configuration (fig. 3), and step 155 includes providing a second battery cell support 30 in a second configuration (fig. 4). In some embodiments, the battery pack 10 may be assembled on an assembly line such that an assembler may choose to couple either the first battery cell holder 30 in the first configuration or the second battery cell holder 30 in the second configuration to the housing lower portion 25 (step 160). For example, if the assembler desires to manufacture a higher output battery pack 10 (e.g., a 15Ah battery pack), the assembler chooses to couple the first battery cell bracket 30 in the first configuration to the housing lower portion 25. Alternatively, if the assembler desires to manufacture a lower output battery pack 10 (e.g., a 12Ah battery pack), the assembler chooses to couple the second cell bracket 30 in the second configuration to the housing lower portion 25. In other embodiments, a first assembly line may be selected to assemble the first cell holder 30 with the lower housing portion 25, and a second assembly line may be selected to assemble the second cell holder 30 with the lower housing portion 25.

Next, the selected first or second cell holder 30 is secured to the housing lower portion 25 (step 165). In particular, if the selected battery cell holder 30 is the first battery cell holder 30 in the first configuration, the first battery cell holder 30 is inserted into the cavity 55 of the housing lower portion 25 such that the posts 100 are aligned with the mounting apertures 115. For example, the

posts

100a, 100b are aligned with the mounting apertures 115a such that each post 100a, 100b engages a corresponding four of the projections 135. The engagement between the tab 135 and the

posts

100a, 100b positions the post apertures 110 and the corresponding mounting apertures 115b of the

Claims

1. A battery pack configured to be coupled to a power tool, the battery pack comprising:

a battery cell support including a first bracket and a second bracket, the first bracket and the second bracket configured to be spaced a first distance relative to each other to support a plurality of first battery cells therebetween, the first bracket and the second bracket configured to be spaced a second distance relative to each other to support a plurality of second battery cells therebetween;

a housing comprising a cavity configured to receive the battery cell support when the first bracket and the second bracket are spaced apart by the first distance, the cavity configured to receive the battery cell support when the first bracket and the second bracket are spaced apart by the second distance;

a plurality of mounting posts coupled to one of the housing and the battery cell holder; and

a plurality of mounting apertures formed in the other of the housing and the battery cell holder,

wherein the plurality of mounting apertures are configured to enable the first bracket and the second bracket to be secured to the housing when the first bracket and the second bracket are spaced apart by the first distance, wherein the plurality of mounting apertures are configured to enable the first bracket and the second bracket to be secured to the housing when the first bracket and the second bracket are spaced apart by the second distance.

2. The battery pack of claim 1, wherein the plurality of mounting apertures are formed in the housing, and wherein a shape of a first mounting aperture of the plurality of mounting apertures is different from a shape of a second mounting aperture of the plurality of mounting apertures.

3. The battery pack of claim 2, wherein the first mounting aperture is circular and the second mounting aperture is non-circular.

4. The battery pack of claim 3, wherein the housing includes a plurality of tabs spaced around the first mounting aperture, and wherein the plurality of tabs engage a first mounting post of the plurality of mounting posts to position the plurality of mounting posts relative to the plurality of mounting apertures.

5. The battery pack of claim 1, wherein the first bracket and the second bracket are configured to support the first plurality of battery cells, wherein each battery cell of the first plurality of battery cells comprises a first length, and wherein the first bracket and the second bracket are configured to support the second plurality of battery cells, wherein each battery cell of the second plurality of battery cells comprises a second length that is shorter than the first length.

6. The battery pack of claim 1, further comprising a plurality of fasteners securing the battery cell holder to the housing via the plurality of mounting posts and the plurality of mounting apertures.

7. The battery pack of claim 6, wherein the plurality of fasteners are screws.

8. A battery pack configured to be coupled to a power tool, the battery pack comprising:

a housing including a cavity;

a battery cell support including a first bracket and a second bracket supporting a plurality of battery cells therebetween, the battery cell support configurable in different configurations based on a size of the plurality of battery cells supported between the first bracket and the second bracket; and

a plurality of mounting features between the housing and the battery cell support, the plurality of mounting features configured to alternatively secure a different configuration of the battery cell support to the housing.

9. The battery pack of claim 8, wherein the plurality of mounting features comprise mounting posts and mounting apertures.

10. The battery pack of claim 9, wherein a shape of a first mounting aperture of the plurality of mounting apertures is different than a shape of a second mounting aperture of the plurality of mounting apertures.

11. The battery pack of claim 10, wherein the first mounting aperture is circular and the second mounting aperture is non-circular.

12. The battery pack of claim 10, wherein the plurality of mounting features comprises a plurality of tabs spaced around at least one of the plurality of mounting apertures, and wherein the plurality of tabs engage a first mounting post of the plurality of mounting posts to position the plurality of mounting posts relative to the plurality of mounting apertures.

13. The battery pack of claim 12, wherein the plurality of mounting posts are coupled to the battery cell bracket, wherein the plurality of mounting apertures are formed in the housing, and wherein the plurality of protrusions are coupled to the housing.

14. The battery pack of claim 8, wherein the battery cell support is configurable in different configurations based on a length of the plurality of battery cells supported between the first bracket and the second bracket.

15. The battery pack of claim 9, wherein the plurality of mounting features comprise a plurality of fasteners that secure the battery cell holder to the housing via the plurality of mounting posts and the plurality of mounting apertures.

16. The battery pack of claim 15, wherein the plurality of fasteners are screws.

17. A method of manufacturing a battery pack configured to be coupled to a power tool, the method comprising:

providing a housing comprising a cavity;

providing a first battery cell holder comprising a plurality of first battery cells, each battery cell of the plurality of first battery cells comprising a first length, the first battery cell holder configured to be coupled to the housing;

providing a second battery cell holder comprising a plurality of second battery cells, each battery cell of the plurality of second battery cells comprising a second length different from the first length, the second battery cell holder configured to be coupled to the housing;

selectively coupling the first battery cell support or the second battery cell support to the housing; and

fixing the selected battery cell holder to the case.

18. The method of claim 17, further comprising aligning a plurality of mounting features between the selected battery cell bracket and the housing, wherein the plurality of mounting features includes a plurality of mounting posts and a plurality of mounting apertures, wherein the plurality of mounting posts are coupled to one of the selected battery cell bracket and the housing, and wherein the plurality of mounting apertures are formed in the other of the selected battery cell bracket and the housing.

19. The method of claim 18, wherein securing the selected battery cell bracket to the housing includes coupling fasteners between the plurality of mounting apertures and the plurality of mounting posts.

20. The method of claim 19, wherein the plurality of mounting apertures are formed in the housing, and wherein the plurality of mounting posts are coupled to the selected battery cell bracket.